Single-Circuit EV Brake Layout With Motor Emergency Braking
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Solution Overview
Problem
Existing electric and hybrid vehicles with dual-circuit pneumatic or hydraulic braking systems face increased weight, manufacturing costs, and complexity due to redundancy requirements, while also occupying more space and complicating on-board electronics.
Innovation Solution
A single-circuit pneumatic braking system connected to all wheels with an electric machine that can act as an emergency service brake, monitored by sensors for proper functioning, allowing regenerative braking to ensure reliable stoppage even in system failures, and incorporating a parking brake device for additional safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a dual-circuit pneumatic or hydraulic braking system is used to provide redundancy and reliable braking, then the braking reliability is improved, but the vehicle weight increases
Solution Approach 1:
The patent merges the functions of the pneumatic/hydraulic braking system with the electric machine (motor-generator) into a unified braking system. The electric machine can operate as a service brake during normal operation and as an emergency brake if the pneumatic/hydraulic system fails, eliminating the need for a separate dual-circuit system while maintaining braking reliability.
Solution Approach 2:
The electric machine is designed with multi-functionality, serving both as a propulsion device and as a braking device. It can provide regenerative braking during normal operation and emergency braking if the pneumatic/hydraulic system fails, replacing the need for dedicated redundant braking circuits.
2Reliability
If a dual-circuit pneumatic or hydraulic braking system is used to provide redundancy, then the braking reliability is improved, but the manufacturing costs increase
Solution Approach 1:
The patent combines the braking functions into a single integrated system using the existing electric machine and a simplified single-circuit pneumatic/hydraulic system. This merger reduces the number of components needed (eliminating the second independent circuit), thereby reducing manufacturing costs while maintaining safety through the electric machine's emergency braking capability.
Solution Approach 2:
The electric machine's multi-functionality allows it to serve as both the primary service brake and the emergency brake, eliminating the need for expensive redundant pneumatic/hydraulic circuits and their associated control systems, thus reducing overall manufacturing costs.
3Reliability
If a dual-circuit pneumatic or hydraulic braking system is used to provide redundancy, then the braking reliability is improved, but the device complexity increases
Solution Approach 1:
The patent merges the emergency braking function into the existing electric machine control system, eliminating the need for separate dual-circuit pneumatic/hydraulic systems and their complex interconnections. The control unit manages both normal and emergency braking through a single integrated architecture, significantly reducing system complexity.
Solution Approach 2:
The electric machine's control system is designed to handle multiple braking functions (service braking and emergency braking) through a single control unit, eliminating the need for separate control systems for each circuit and reducing overall device complexity.
4Reliability
If a dual-circuit pneumatic or hydraulic braking system is used to provide redundancy, then the braking reliability is improved, but the installation space required increases
Solution Approach 1:
The patent merges the emergency braking functionality into the existing electric machine and its control systems, eliminating the need for separate dual-circuit pneumatic/hydraulic components and their associated installation space. The single-circuit system requires significantly less space while maintaining safety through integrated emergency braking.
5Reliability
If a dual-circuit pneumatic or hydraulic braking system is used to provide redundancy, then the braking reliability is improved, but the on-board electronics complexity increases
Solution Approach 1:
The patent merges the emergency braking control into the existing electric machine control unit, eliminating the need for separate control electronics for dual-circuit braking systems. The single control unit manages both normal and emergency braking functions, significantly reducing on-board electronics complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution simplifies the braking system, reduces weight and space, ensures reliable braking, and enables energy recovery through regenerative braking, while maintaining safety redundancy and allowing for more passenger compartment space.
Implementation Method 1
at least one electric machine operable as an electric motor and generator
Implementation Method 2
a pneumatic braking device which can act to brake at least two wheels by means of brake actuators
Data Source
Figure 1~2
AI summary
The invention relates to a brake system (40) of an electric vehicle (10) or hybrid vehicle, which has at least two driven wheels (12, 14) and at least two steerable wheels (16, 18), at least two wheels (12, 14, 16, 18) of which can be driven by means of at least one electric machine (20, 22) which can be driven as an electric motor and as a generator, and which brake system (40) has a fluidic brake device (42) which can act by means of brake actuators (46, 48, 50, 52) on at least two wheels (12, 14, 16, 18) in order to brake the latter. According to the invention there is provision that the fluidic brake device (42) has just one brake circuit (44) which is connected to the brake actuators (46, 48, 50, 52) on all the wheels (12, 14, 16, 18), and that the at least one electric machine (20, 22) is embodied and can be operated in such a way that in the event of a fault in the fluidic brake device (42) said electric machine (20, 22) can be activated as an emergency service brake, wherein the fluidic brake device (42) and the at least one electric machine (20, 22) are embodied in such a way that they can brake the electric vehicle (10) or the hybrid vehicle as far as the stationary state.